Volvo EC15B mini - engine removal & injection pump overhaul - plus ......

[Stock]

So has the cam been wrong from day one?

[jackpreacher]

IP camshaft alignment problem

I think your holding it the wrong way round, because I can see where the cam lobes have struck the IP plunger bases ... so why has that happened ? .. is the bearing on the cam shaft humped? .. or is there some alignment problem that I was mentioning earlier ? .. perhaps a thrust bearing not fitted properly on the shaft ? (since the drive teeth are helical)

I think I found the answer to this Muz -

The engine seals kit and secondhand timing camshaft have arrived. Here is the comparison between the old and 'new'
Timing Camshaft Comparison.jpg
The gap in my original camshaft - that gap between the bearing and the lobe shoulder - is the reason why my cam has been eccentrically connecting with the IP plungers.

old camshaft in situ.jpg
Old Camshaft in Situ


new camshaft in situ.jpg
New camshaft in situ.

The difference is possibly 10mm, or maybe even 13mm.

TBC

[Gridley]

Ok, do you want the list of family members?

No,I`ll pick it up eventually.
I`ve actually got a mate in the States who`s nickname is Digger Doug.

[jackpreacher]

I was several pages in to this wondering who Doug was and thinking he`s somebody else with the same problem before the penny dropped.

That made me giggle out loud!!

Ok, do you want the list of family members?

[Gridley]

WTF`s Doug

I was several pages in to this wondering who Doug was and thinking he`s somebody else with the same problem before the penny dropped.

[Muz]

I'm not so sure about the pump failing to put out the right pressures now, when I see where the lobes have got their wear from .. essentially the lobe will still have been delivering pressure at the right time, although the wear on the lobes is still wrong and somethings amiss

[jackpreacher]

I think your holding it the wrong way round

You're absolutely right, I'm holding it the opposite way round. The thrust washer, or lack of it, is something I'll investigate tomorrow. Thanks for mentioning it - never knew it may have one

[Muz]

I think your holding it the wrong way round, because I can see where the cam lobes have struck the IP plunger bases ... so why has that happened ? .. is the bearing on the cam shaft humped? .. or is there some alignment problem that I was mentioning earlier ? .. perhaps a thrust bearing not fitted properly on the shaft ? (since the drive teeth are helical)

[jackpreacher]

IP and timing camshaft

Here is a few close ups of the IP and it's camshaft and how the cam lobes activate the IP plungers:

IP and camshaft 1.jpg

IP and camshaft damage.jpg

IP and camshaft with bloody big red arrow in case you're a blind man on a galloping horse!.jpg

TBC

[jackpreacher]

Smart thinking there Jack.................

........and fiendishly handsome.....

[Stock]

I'm not, but it does read that way! I was really enquiring because Muz couldn't get one for under £1200 and thought he may still have enough bits from his goosed engine to make a spare up..

Smart thinking there Jack.................

[jackpreacher]

Why are you changing the Crank??

I'm not, but it does read that way! I was really enquiring because Muz couldn't get one for under £1200 and thought he may still have enough bits from his goosed engine to make a spare up..

[Stock]

We are getting there Muzz.....

[Muz]

What an epic EC15 thread this is .....

[Stock]

Why are you changing the Crank??